Processes for making polyisobutylene compositions

ABSTRACT

Methods of making polyisobutylene and catalyst systems are described. Polyisobutylene compositions and catalyst system compositions are also described. In some embodiments, a method of making a catalyst system includes: providing a support material comprising one or more ion exchange resins; dehydrating the support material; and forming a catalyst system by adding to the support material (a) a mixture comprising BF 3 , (b) a mixture comprising BF 3  and a complexing agent, or (c) both. In some embodiments, a method of making a polymer composition includes providing a catalyst system comprising: (a) a support material comprising one or more ion exchange resins, and (b) BF 3 ; providing a feedstock comprising isobutylene; forming a reaction mixture comprising the feedstock and the catalyst system; contacting the isobutylene with the catalyst system; and obtaining a polymer composition.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/090,092, issued as U.S. Pat. No. 10,640,590, filed Sep. 28, 2018,which is a continuation of International Application No.PCT/US2018/018808, filed Feb. 20, 2018, which claims benefit of U.S.Provisional Patent Application No. 62/600,388, filed Feb. 21, 2017 andto U.S. Provisional Patent Application No. 62/606,023, filed Sep. 6,2017, each of which is incorporated by reference herein in its entirety.

This application is related to another U.S. application, filed on evendate herewith, and identified by the following title: entitled“Processes for Making Polyisobutylene Compositions”, which isincorporated by reference herein in its entirety.

FIELD

The present disclosure relates to highly-reactive polyisobutylene(HR-PIB) compositions. The present disclosure also relates to catalystsystems and methods for forming HR-PIB compositions.

BACKGROUND

Common methods to polymerize isobutylene and form polyisobutylene (PIB)with one carbon-carbon double bond include using Lewis acid catalysts,such as boron trifluoride (BF₃) and aluminum trichloride (AlCl₃). Thedouble bond can be located at the end of the polymer chain (e.g., alphavinylidenes) or it can be located more internal in the chain as in betavinylidene or other trisubstituted olefin isomers, or tetra substitutedolefin isomers. PIB containing a high proportion of alpha vinylideneolefin isomers is referred to as highly reactive polyisobutylene(HR-PIB). Such polymer molecules are more reactive in subsequentderivatization reactions to produce derivatives such as fuel andlubricant additives than other types of PIB.

Conventional AlCl₃ catalysts typically produce PIB that has olefinisomers other than alpha vinylidene. These PIB products are known asconventional PIB and are significantly less reactive in derivatizationreactions.

Catalyst complexes (such as liquid BF₃/complexing agent) have beendeveloped to produce HR-PIB. See U.S. Pat. Nos. 6,525,149; 6,562,913;6,683,138; and 6,884,858. However, many liquid BF₃/complexing agents areunstable and must be prepared in situ, requiring the handling of highlytoxic BF₃ gas on site. The liquid BF₃/complexing agents must also beremoved post-reaction by extensive water washing processes which arehighly complex and generate large amounts of waste water. Moreover, thewaste water contains fluoride salts that require disposal.

U.S. Pat. Nos. 8,791,216 and 8,816,028 describe polyisobutylenecompositions, and methods and catalyst systems to produce suchcompositions. The catalyst system is a solid BF₃/alcohol catalystcomplex on a metal oxide support material of gamma alumina beads orspheres, and the catalyst system is used in a fixed bed reactor. The PIBproducts made include internal vinylidene isomers and alpha vinylideneisomers, such that the alpha vinylidene olefin isomers in thesecompositions are significantly less than 75 wt %.

U.S. Pat. No. 9,040,645 discloses a method of preparing alumina withpores and reacting BF₃/methanol complexes with the porous alumina. TheBF₃/methanol/alumina catalyst system produces PIB compositions in whichthe alpha vinylidene isomer content is significantly less than 75 wt %.

Other references that describe conventional PIB processes and catalystsinclude: U.S. Pat. Nos. 5,710,225; 5,945,575; 6,384,164; 6,441,110;6,710,140; and 6,992,152.

There exists a need for an improved process to produce HR-PIBcompositions having an alpha vinylidene olefin isomer content greaterthan about 75% and catalyst for producing such materials.

SUMMARY

In at least one embodiment, a method of making a catalyst system isprovided. The method includes providing a support material comprisingone or more ion exchange resins; dehydrating the support material at atemperature of about 30° C. to about 200° C.; and forming a catalystsystem by adding to the support material (a) a mixture comprising BF₃,(b) a mixture comprising BF₃ and a complexing agent, or (c) both.

In at least one embodiment, a catalyst system is provided. The catalystsystem includes a support material comprising one or more ion exchangeresins; and BF₃, wherein a concentration of BF₃ is greater than about 25wt %, based on a total weight of the catalyst system.

In at least one embodiment, a method of making a polymer composition isprovided. The method includes providing a catalyst system comprising:(a) a support material comprising one or more ion exchange resins, and(b) BF₃; providing a feedstock comprising isobutylene; forming areaction mixture comprising the feedstock and the catalyst system;contacting the isobutylene with the catalyst system; and obtaining apolymer composition.

In an embodiment, a method of making a catalyst system is provided. Themethod includes providing a support material selected from the groupconsisting of Al₂O₃, ZrO₂, TiO₂, SnO₂, CeO₂, SiO₂, SiO₂/Al₂O₃, andcombinations thereof; calcining the support material at a temperature ofabout 450° C. to about 900° C.; and forming a catalyst system by addingto the support material (a) a mixture comprising BF₃, (b) a mixturecomprising BF₃ and a complexing agent, or (c) both.

In at least one embodiment, a method of making a catalyst system isprovided. The method includes providing a support material selected fromthe group consisting of Al₂O₃, ZrO₂, TiO₂, SnO₂, CeO₂, SiO₂, SiO₂/Al₂O₃,and combinations thereof, the support material calcined at a temperatureof about 450° C. to about 900° C.; and forming a catalyst system byadding to the support material (a) a mixture comprising BF₃, (b) amixture comprising BF₃ and a complexing agent, or (c) both.

In at least one embodiment, a catalyst system is provided. The catalystsystem includes a support material selected from the group consisting ofAl₂O₃, ZrO₂, TiO₂, SnO₂, CeO₂, SiO₂, SiO₂/Al₂O₃, and combinationsthereof; and BF₃, wherein a concentration of BF₃ is greater than about25 wt %, based on the total weight of the catalyst system.

In at least one embodiment, a method of making a polymer composition isprovided. The method includes providing a catalyst system comprising:(a) a support material selected from the group consisting of Al₂O₃,ZrO₂, TiO₂, SnO₂, CeO₂, SiO₂, SiO₂/Al₂O₃, and combinations thereof; and(b) BF₃; providing a feedstock comprising isobutylene; forming areaction mixture comprising the feedstock and the catalyst system;contacting the isobutylene with the catalyst system; and obtaining apolymer composition.

BRIEF DESCRIPTION OF THE FIGURES

So that the manner in which the above recited features of the presentdisclosure can be understood in detail, a more particular description ofthe disclosure, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlyexemplary embodiments and are therefore not to be considered limiting ofits scope, for the disclosure may admit to other equally effectiveembodiments.

FIG. 1A shows a block diagram of a process to form a catalyst systemaccording to some embodiments.

FIG. 1B shows a block diagram of a process to form a catalyst systemaccording to some embodiments.

FIG. 1C shows a block diagram of a process to form a catalyst systemaccording to some embodiments.

FIG. 2A shows a block diagram of a process to form a polymer compositionaccording to some embodiments.

FIG. 2B shows a block diagram of a process to form a polymer compositionaccording to some embodiments.

DETAILED DESCRIPTION

The present disclosure relates to catalyst compositions and processes tomake polyisobutylenes (PIB), and particularly highly reactivepolyisobutylene (HR-PIB). The present disclosure also relates to PIBcompositions, particularly HR-PIB compositions.

For purposes of this disclosure, HR-PIB is a composition containinggreater than about 75% alpha vinylidene olefin isomer. The HR-PIBcompositions can contain additional olefin isomers including betavinylidene olefin isomer, other trisubstituted olefin isomers, internalvinylidenes, and tetrasubstituted olefin isomers. HR-PIB is termedhighly reactive because of its increased reactivity in derivatizationreactions, such as reactions with maleic anhydride to producepolyisobutenylsuccinic anhydride (PIBSA) to form precursors useful forfuel and lubricant additives.

For purposes of this application, molecular structures may berepresented by bond-line structure (also known as skeletal structure) inwhich the position of carbon and hydrogen atoms may be implied.

For purposes of this application, an alpha vinylidene olefin isomer(also referred to as α-vinylidene) has the following structure:

For purposes of this application, a beta vinylidene olefin isomer (alsoreferred to as β-vinylidene) has the following structure:

For purposes of this application, an internal disubstituted vinylideneolefin isomer includes the following structure:

Other internal vinylidenes are possible, including where the position ofthe olefin in the polyisobutylene is such that the olefin isdisubstituted and not at the end of the carbon chain. For purposes ofthis application other trisubstituted olefin isomers andtetrasubstituted olefin isomers may be produced in the polymerizationsdescribed herein.

As used herein, an “olefin,” alternatively referred to as “alkene,” is alinear, branched, or cyclic compound of carbon and hydrogen having atleast one carbon-carbon double bond. For purposes of this specificationand the claims appended thereto, when a polymer or copolymer is referredto as comprising an olefin, the polymer or copolymer has polymermolecules that have at least one olefin bond.

A “polymer” has two or more of the same or different monomer (“mer”)units bonded together in a single polymer molecule, or a collection ofsuch polymer molecules. A “homopolymer” is a polymer having mer unitsthat are the same. A “copolymer” is a polymer having two or more merunits that are different from each other. “Different” as used to referto mer units indicates that the mer units differ from each other by atleast one atom or are different isomerically.

As used herein, Mn is number average molecular weight, Mw is weightaverage molecular weight, wt % is weight percent, and mol % is molepercent. Unless otherwise noted, all molecular weight units (e.g., Mwand Mn) are daltons (Da).

As used herein, a “catalyst” includes a single catalyst, or multiplecatalysts with each catalyst being conformational isomers orconfigurational isomers. Conformational isomers include, for example,conformers and rotamers. Configurational isomers include, for example,stereoisomers.

The term “catalyst complex” refers to a complex of a catalyst and acomplexing agent. Catalyst complex includes a single catalyst complex ormultiple catalyst complexes.

The term “catalyst system” refers to a composition comprising a catalystand a support material. Catalyst system also refers to a compositioncomprising a catalyst complex with a support material. When catalystsystems are described (including by structure or formula) as comprisingneutral stable forms of the components, it is well understood by one ofordinary skill in the art, that the form that reacts with the polymerprecursors to produce polymers may be a reactive form that resultsdirectly from proper use of the catalyst system.

Furthermore, catalysts of the present disclosure (which may berepresented by a formula and/or a structure) are intended to embraceionic, reactive, or reaction product forms of the catalysts in additionto the neutral forms of the catalysts. Furthermore, complexing agents ofthe present disclosure (which may be represented by a formula and/or astructure) are intended to embrace ionic, reactive, or reaction productforms of the complexing agents in addition to neutral forms of thecomplexing agents. Moreover, catalyst systems of the present disclosure(which may be represented by a formula and/or a structure) are intendedto embrace ionic, reactive, or reaction product forms of the catalystsystems in addition to neutral forms of the catalyst systems.

As used herein, composition includes components of the compositionand/or reaction products thereof.

A catalyst system, when made, sold, or used includes about 25% to about45% of BF₃.

Unless otherwise indicated, the term “substituted” generally refers to ahydrogen of the substituted species being (or has been) replaced with adifferent atom or group of atoms.

The following abbreviations may be used herein: Me is methyl; Et isethyl; Pr is propyl; nPr is normal propyl; iPr is isopropyl; Bu isbutyl; nBu is normal butyl; iBu is isobutyl; sBu is sec-butyl; tBu istert-butyl; THF (also referred to as thf) is tetrahydrofuran; MeOH ismethanol; MTBE (also referred to as mtbe) is methyl tert-butyl ether; RTis room temperature (and is between about 15° C. and about 25° C. unlessotherwise indicated).

The terms “hydrocarbyl radical,” “hydrocarbyl,” “hydrocarbyl group,”“alkyl radical,” “alkyl,” and “alkyl group” may be used herein, and ifused, are used interchangeably. Likewise, the terms “group,” “radical,”and “substituent” are also used interchangeably in this document,referring only to chemical groups that are attached to other chemicalstructures, implying nothing about the state, structure, charge, orcondition of such groups when not attached to other chemical structures.For purposes of this disclosure, “hydrocarbyl radical” refers to C₁-C₁₀₀radicals, that may be linear, branched, or cyclic, and when cyclic,aromatic or non-aromatic. Examples of such radicals include methyl,ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl,pentyl, iso-amyl, hexyl, octyl, cyclopropyl, cyclobutyl, cyclopentyl,cyclohexyl, cyclooctyl, benzyl, and their substituted analogues.Substituted hydrocarbyl radicals are radicals in which at least onehydrogen atom of the hydrocarbyl radical has been substituted with atleast one halogen (such as Br, Cl, F or I) or at least one functionalgroup such as C(O)R*, C(O)NR*₂, C(O)OR*, NR*₂, OR*, SeR*, TeR*, PR*₂,AsR*₂, SbR*₂, SR*, BR*₂, SiR*₃, GeR*₃, SnR*₃, and PbR*₃ (where R* isindependently a hydrogen or hydrocarbyl radical, and two or more R* mayjoin together to form a substituted or unsubstituted saturated,partially unsaturated or aromatic cyclic or polycyclic ring structure),or where at least one heteroatom has been inserted within a hydrocarbylring.

The term “alkenyl” may be used herein, and if used, refers to astraight-chain, branched-chain, or cyclic hydrocarbon radical having oneor more double bonds. These alkenyl radicals may be optionallysubstituted.

The term “aryl” or “aryl group” may be used herein, and if used,includes a C₄-C₂₀ aromatic ring, such as a six carbon aromatic ring, andthe substituted variants thereof, including phenyl, 2-methyl-phenyl,xylyl, 4-bromo-xylyl. Likewise heteroaryl refers to an aryl group wherea ring carbon atom (or two or three ring carbon atoms) has been replacedwith a heteroatom, for example, N, O, or S. As used herein, the term“aromatic” also refers to pseudoaromatic heterocycles which areheterocyclic substituents that have similar properties and structures(nearly planar) to aromatic heterocyclic ligands, but are not bydefinition aromatic; likewise the term aromatic also refers tosubstituted aromatics.

The term “Ring structure” may be used herein, and if used, refers toatoms bonded together in one or more cyclic arrangements.

The term “ring atom” may be used herein, and if used, refers to an atomthat is part of a cyclic ring structure. By this definition, a benzylgroup has six ring atoms and tetrahydrofuran has 5 ring atoms.

The term “heterocyclic ring” may be used herein, and if used, refers toa ring having a heteroatom in the ring structure as opposed to aheteroatom-substituted ring where a hydrogen on a ring atom is replacedwith a heteroatom. For example, tetrahydrofuran is a heterocyclic ringand 4-N,N-dimethylamino-phenyl is a heteroatom-substituted ring.

As used herein, the term “aromatic” also refers to pseudoaromaticheterocycles which are heterocyclic structures that have similarproperties and structures (nearly planar) to aromatic heterocyclicligands, but are not by definition aromatic; likewise, the term aromaticalso refers to substituted aromatics.

The term “continuous” refers to a system that operates withoutinterruption or cessation while performing a particular process forwhich the system is designed. For example, a continuous process toproduce a polymer would be one where the reactants are continuallyintroduced into one or more reactors and polymer product is continuallywithdrawn during a polymerization process.

A solution polymerization refers to a polymerization process in whichthe polymer is dissolved in a liquid polymerization medium, such as anunreactive solvent or polymerizable compounds (including polymerprecursors) or their blends.

A bulk polymerization refers to a polymerization process in which theprecursors being polymerized are used as a solvent or diluent usinglittle or no unreactive solvent as a solvent or diluent. A smallfraction of unreactive solvent might be used as a carrier for a catalystsystem. A bulk polymerization system contains less than about 25 wt % ofunreactive solvent or diluent, for example, less than about 10 wt %,less than about 1 wt %, or about 0 wt %.

As used herein the term “slurry polymerization process” refers to apolymerization process where a supported catalyst is employed andpolymer precursors are polymerized on the supported catalyst particles.

“Homopolymerization” would produce a polymer made from one type ofpolymerizable compounds (including polymer precursors), whereas“copolymerization” would produce polymers with more than onepolymerizable compound type.

Catalyst Complexes

Catalysts for the polymerization processes described herein includeLewis acids, such as BF₃. The catalysts described herein are capable offorming polyisobutylenes (PIB) and particularly HR-PIBs.

The catalyst complexes described herein, like the Lewis acid catalysts,are capable of forming PIB and particularly HR-PIBs. Some of thedisclosed catalyst complexes include a Lewis acid (for example, BF₃) anda complexing agent.

In some embodiments, the Lewis acid catalyst is complexed with acomplexing agent. Alternately, the Lewis acid catalyst can be usedwithout a complexing agent. The catalyst systems described herein aresolids, for example powders. The solid catalyst systems described hereinare formed by contacting the Lewis acid catalyst alone (e.g., BF₃ gas)with a support material, or by complexing the Lewis acid catalystcomplex (e.g., BF₃/complexing agent) with a support material.

Complexing agents include linear, branched, cyclic, heterocyclic (forexample, tetrahydrofuran and tetrahydropyran), aryl (such as phenol andbenzyl alcohol), and heteroaryl compounds.

In some embodiments, the complexing agent is a compound that has a lonepair of electrons (such as oxygen containing compounds and nitrogencontaining compounds). Nitrogen containing compounds include amines,polyamines (such as ethylene diamine), amides, polyamides, amino acids,polyamino acids, and polyaminocarboxylic acids such as ethylenediaminetetracetic acid (EDTA). In some embodiments, the nitrogen containingcompound is an unsubstituted C₁ to C₂₀ amine (such as alkylamines,including methyl amine, ethyl amine, propyl amine, decyl amine andlauryl amine), a substituted C₁ to C₂₀ amine, including alkanol amines(such as ethanol amine, diethanol amine, triethanol amine, propanolamine, diethylethanol amine), an unsubstituted C₂ to C₂₀ polyamine (suchas diethylenetriamine, triethylenetetramine, tetraethylenepentamine, andheavy polyamine X (HPA X)), a substituted C₂ to C₂₀ polyamine, anunsubstituted C₁ to C₂₀ amide (such as formamide, acetamide,2-propenamide, and benzamide), a substituted C₁ to C₂₀ amide (such asN,N-dimethylformamide (DMF), N,N-dimethypropanamide, N-methylacetamide,and N-phenylacetamide), aliphatic polyamides (such as Nylon 6 and Nylon66), polyphthalamides (such as hexamethylenediamine terepthalate),aramids (such as Kevlar and Nomex), an amino acid (such as the 20standard amino acids, for example aspartic acid and glycine), apolyamino acid (such as poly(hydroxypropyl-L-glutamine) andpoly-L-leucine), polyaminocarboxylic acids.

Oxygen containing compounds (also known as oxygenates) that may be usedinclude alcohols, ethers, ketones, aldehydes, and carboxylic acids. Insome cases, the complexing agent is an oxygen containing compound suchas an alcohol or an ether (symmetrical or asymmetrical). In other cases,the complexing agent is a C₁ to C₁₀ unsubstituted alcohol, a C₁ to C₁₀substituted alcohol, a C₂ to C₂₀ unsubstituted ether, or a C₂ to C₂₀substituted ether.

In some cases, the complexing agent is an alcohol that lacks a betahydrogen such as methanol, 2,2-dimethyl alcohols (for example, neopentylalcohol, 2,2-dimethylbutanol, 2,2-dimethylpentanol, and2,2-dimethylhexanol), benzyl alcohol, and ring-substituted benzylalcohols.

In some embodiments, the complexing agent contains more than one oxygencontaining group per molecule, for example, glycols (substituted orunsubstituted) and polyols (substituted or unsubstituted), for examplewherein each hydroxyl is in a primary position, or for example, a C₁ toC₁₀ glycol (substituted or unsubstituted) such as ethylene glycol,1,4-butanediol, trimethylolethane(2-(hydroxymethyl)-2-methylpropane-1,3-diol; C₅H12O₃),trimethylolpropane (2-(hydroxymethyl)-2-ethylpropane-1,3-diol; C₆H₁₄O₃),pentaerythritol (2,2-bis(hydroxymethyl)propane-1,3-diol; C₅H₁₂O₄), andtris(hydroxymethyl)aminomethane (C₄H₁₁NO₃).

In one embodiment, the complexing agent is methanol, ethanol,isopropanol (also known as isopropyl alcohol), n-propanol (also known aspropan-1-ol), neopentyl alcohol (also known as 2,2-dimethyl-1-propanoland neopentanol), dimethyl ether, diethyl ether, diisopropyl ether,diisobutyl ether, di-tert-butyl ether, methyl tert-butyl ether (MTBE),or ethylene glycol. In some cases, the oxygen containing compound ismethanol.

In some embodiments, the catalyst complex (e.g., the BF₃/complexingagent) is formed by passing BF₃ gas through the pure anhydrous oxygencontaining compound (or nitrogen containing compound) at a rate thatallows the BF₃ to be efficiently absorbed.

In some embodiments, the mole ratio of complexing agent to BF₃ isbetween about 0.1 and about 10 in the catalyst complex. In otherembodiments, the mole ratio is between about 0.2 and about 5. In somecases, the mole ratio is between about 0.2 and 2. In other cases, themole ratio is between about 0.5 and about 2, for example between about1.0 and about 1.9. In some embodiments, the mole ratio is between about1.0 and about 1.3, for example, about 1.0.

Support Materials

The catalyst system comprises an unreactive support material. Suitablesupport materials for the catalyst and/or catalyst complex include anysupport material that forms a stable adduct with BF₃. In an embodiment,the support material is a porous support material, comprising inorganicoxides. Other suitable support materials are the metal oxides doped withrare earth metals or rare earth metals themselves or combinations ofboth.

In some embodiments, the support material is an inorganic oxide in afinely divided form, such as a powder. Suitable inorganic oxidematerials for use in catalyst systems herein include metal oxides ofGroup IIIA, Group IVA, and Group IVB of the Periodic Table of theElements, such as alumina, silica, and titania, and mixtures thereof.Inorganic oxides may be employed either alone or in combination with thesilica or alumina including titania and zirconia. Combinations of thesupport materials may be used, for example, silica-alumina, andsilica-titania. In some embodiments, support materials include Al₂O₃,ZrO₂, TiO₂, SnO₂, CeO₂, SiO₂, SiO₂/Al₂O₃, and combinations thereof. Insome embodiments, support materials include SiO₂, Al₂O₃, SiO₂/Al₂O₃, orcombinations thereof.

In some embodiments, the support material has one or more of thefollowing properties:

1) at least about 1% Al₂O₃ by weight (for example, greater than about 3wt %, such as greater than about 5 wt %, greater than about 10 wt %,greater than about 15 wt %, greater than about 20 wt %, greater thanabout 25 wt %, greater than about 30 wt %, greater than about 35 wt %,greater than about 40 wt %, greater than about 45 wt %, or greater thanabout 50 wt %), based on the total weight of the support material.Alternately, the support material has less than about 99 wt % SiO₂ (forexample, less than about 97 wt %, such as less than about 95 wt %, lessthan about 90 wt %, less than about 85 wt %, less than about 80 wt %,less than about 75 wt %, less than about 70 wt %, less than about 65 wt%, less than about 60 wt %, less than about 55 wt %, or less than about50 wt %), based on the total weight of the support material.Alternately, the support material has an Al₂O₃ of wt % ranges withinthose aforementioned weight percents.

2) at least about 1% SiO₂ by weight (for example, greater than about 3wt %, such as greater than about 5 wt %, greater than about 10 wt %,greater than about 15 wt %, greater than about 20 wt %, greater thanabout 25 wt %, greater than about 30 wt %, greater than about 35 wt %,greater than about 40 wt %, greater than about 45 wt %, or greater thanabout 50 wt %), based on the total weight of the support material.Alternately, the support material has less than about 99 wt % SiO₂ (forexample, less than about 97 wt %, such as less than about 95 wt %, lessthan about 90 wt %, less than about 85 wt %, less than about 80 wt %,less than about 75 wt %, less than about 70 wt %, less than about 65 wt%, less than about 60 wt %, less than about 55 wt %, or less than about50 wt %), based on the total weight of the support material.Alternately, the support material has a SiO₂ content of wt % rangeswithin those aforementioned weight percents.

3) a surface area greater than about 10 m²/g (for example, between about10 m²/g and about 700 m²/g, such as between about 50 m²/g and about 500m²/g, or between about 100 m²/g and about 400 m²/g). Alternately, thesurface area is greater than about 150 m²/g.

4) a pore volume greater than about 0.1 cc/g (for example, between about0.1 cc/g and about 4.0 cc/g, such as between about 0.5 cc/g and about3.5 cc/g, or between about 0.8 cc/g and about 3.0 cc/g).

5) a monodispersed particle size or a distribution of particle sizeswith an average particle size greater than about 5 μm (for example,between about 5 μm and about 500 μm, such as between about 5 μm andabout 200 μm, or between about 10 μm and about 100 μm).

6) an average pore size (diameter) greater than about 1 nm (for example,between about 1 nm and about 100 nm, such as between about 5 nm andabout 50 nm, or between about 7.5 nm and about 35 nm). Alternately, thepore size is greater than about 20 nm.

7) a pore volume greater than about 0.3 cc/g (for example, greater thanabout 0.5 cc/g or greater than about 1.0 cc/g).

8) less than about 5 wt % Fe₂O₃ (for example, less than about 1 wt %,such as less than about 0.5 wt %, or less than about 0.2 wt %), based onthe total weight of the support material.

9) less than about 5 wt % Na₂O (for example, less than about 1 wt %,such as less than about 0.5 wt %, less than about 0.2 wt %, or less thanabout 0.02), based on the total weight of the support material.

In some embodiments, the support material is a high surface area,amorphous silica (for example, the surface area is about 300 m²/g andthe pore volume is about 1.65 cm³/gm).

Other support materials include the following: gamma-alumina spheres(γ-Al₂O₃); SiO₂/Al₂O₃ (silica-alumina) support material having about 50wt % SiO₂; and a second SiO₂/Al₂O₃ (silica-alumina) support materialhaving about 75 wt % SiO₂. Table 1 shows the physical properties ofthese support materials prior to heating, calcining, and complexing withthe catalyst and/or catalyst complexes.

TABLE 1 Physical Properties of Example Support Materials Gamma- Silica-Silica- Property Alumina Spheres Alumina Alumina Al₂O₃ (wt %) 92.7 50.8525.63 Loss on Ignition 7.0 0.19 0.02 (1000° C. for 1 h) (wt %) SiO₂ (wt%) 0.02 49.15 74.37 Fe₂O₃ (wt %) 0.02 — — Na₂O (wt %) 0.2 0.01 0.01Sphere diameter (mm) 3.2 — — Particle Size: D10 (μm) — 12.25 11.13Particle Size: D50 (μm) — 39.05 38.63 Particle Size: D90 (μm) — 79.0179.53 Packed Bulk Density (g/cm³) 0.769 — — Loose Bulk Density (g/cm³) —0.38 0.28 Surface Area (m²/g) 350 163.9 172.28 Pore Volume (cc/g) 0.501.06 1.45 Pore Diameter (nm) — 25.79 33.48

The support material should be dry, that is, free (or essentially free)of absorbed water before addition of the catalyst or the catalystcomplex. Drying of the support material can be effected by heating orcalcining at a temperature of at least about 25° C. (for example,between about 100° C. and about 1000° C., such as between about 200° C.and 1000° C., between about 250° C. and 1000° C., between about 400° C.and about 900° C., or between about 550° C. and about 700° C.); and fora time of between about 1 minute and about 100 hours (for example,between about 1 minute and about 72 hours, such as between about 1minute and about 60 hours, or between about 2 hours and about 10 hours,such as about 2 hours, about 4 hours, 6 hours, or about 8 hour).

In some embodiments, the support material is calcined when firstmanufactured and/or recalcined as received. The calcined supportmaterial is then contacted with at least one of a mixture comprising BF₃and a mixture comprising BF₃ and complexing agent.

Other support materials that can be used include organic supports thatare a solid or that forms a solid when complexed with BF₃ and/or BF₃ andcomplexing agent. This organic support and can be used instead of, or incombination with the inorganic oxide support material. While not wishingto be bound by theory, it is believed that the organic support, like aninorganic oxide support, provides active sites for the BF₃ and/or BF₃and complexing agent. In some embodiments, this support can be any solidorganic complexing agent containing O or N functionality (or anyfunctionality) that is capable of supporting BF₃ or BF₃ complexes.Alternately, the support can be an organic complexing agent containing Oor N functionality (or any functionality) that forms a solid whencomplexed BF₃ or BF₃ complexes. Examples of such complexing agents thatact as supports include ion exchange resins such as anionic exchangeresins and cationic exchanges resins, including strongly acidic cationexchange resins, weakly acidic cation exchange resins, strongly basicanionic exchange resins, and weakly basic anionic exchange resins. Forexample, Amberlyst™ and Amberlite™ resins (such as Amberlyst 15 sulfonicacid and Amberlite IRA 67 weak base (amine) resin) may be used as thesupport. The ion exchange resins may be used with or without calcining(or otherwise pretreated or heated). Dehydration (or otherwise heating)temperatures of the ion exchange resins include temperatures greaterthan about 25° C. (such as between about 30° C. and about 200° C., forexample between about 100° C. and about 200° C., such as about 150° C.);and for a time of between about 1 minute and about 100 hours (forexample, between about 1 minute and about 72 hours, such as betweenabout 1 minute and about 60 hours, or between about 2 hours and about 10hours, such as about 2 hours, about 4 hours, 6 hours, or about 8 hours).

Catalyst Systems

Some embodiments described herein are catalyst systems. A catalystsystem can be made from any catalyst described herein, any supportmaterial described herein, any complexing agent described herein, and/orany catalyst complex described herein.

In some embodiments, a catalyst system includes BF₃ and a supportmaterial selected from the group consisting of Al₂O₃, ZrO₂, TiO₂, SnO₂,CeO₂, SiO₂, SiO₂/Al₂O₃, and combinations thereof, wherein theconcentration of BF₃ is greater than about 1% by weight (for example,greater than about 5 wt %, such as greater than about 10 wt %, greaterthan about 20 wt %, greater than about 25 wt %, greater than about 30 wt%, greater than about 40 wt %, or greater than about 50 wt %), based onthe total weight of the catalyst system (i.e., BF₃ plus the supportmaterial).

In other embodiments, a catalyst system includes BF₃ and an organicsupport material that is an ion exchange resin (i.e., an anionicexchange resin, a cationic exchanges resins (such as Amberlyst™ andAmberlite™ resins), and/or combinations thereof), wherein theconcentration of BF₃ is greater than about 1% by weight (for example,greater than about 5 wt %, such as greater than about 10 wt %, greaterthan about 20 wt %, greater than about 25 wt %, greater than about 30 wt%, such as about 40 wt %), based on the total weight of the catalystsystem (i.e., BF₃ plus the support material).

In still other embodiments, a catalyst system includes a combination ofinorganic oxide (i.e., Al₂O₃, ZrO₂, TiO₂, SnO₂, CeO₂, SiO₂, SiO₂/Al₂O₃,and combinations thereof) and organic support (i.e., ion exchangeresins, such as anionic and cationic exchange resins for exampleAmberlyst™ and Amberlite™ resins)

The catalyst system can further include a complexing agent, wherein theconcentration of BF₃ is greater than about 1% by weight (for example,greater than about 5 wt %, such as greater than about 10 wt %, greaterthan about 20 wt %, greater than about 25 wt %, greater than about 30 wt%, greater than about 40 wt %, or greater than about 50 wt %), based onthe total weight of the catalyst system (i.e., BF₃ plus the complexingagent plus the support material). The actual concentration of F or B inthe catalyst complex/support material depends on the complexing agentused.

In embodiments where the catalyst system is formed by adding to thesupport material a mixture comprising BF₃ and a complexing agent, themole ratio of complexing agent to BF₃ is at least about 0.1, for examplebetween about 0.1 and about 10. In other embodiments, the mole ratio isbetween about 0.2 and about 5. In some cases, the mole ratio is betweenabout 0.2 and 2. In other cases, the mole ratio is between about 0.5 andabout 2, for example between about 1.0 and about 1.9. In someembodiments, the mole ratio is between about 1.0 and about 1.3, forexample, about 1.0.

In some embodiments, the weight ratio of support material to catalystcomplex is less than about 1:1, for example, less than about 0.5:1, orless than about 0.25:1.

In at least one embodiment, the catalyst composition is 65 wt % (basedon the total weight of the catalyst system) of a 1:1 BF₃—MeOH complex ona SiO₂/Al₂O₃ support containing about 50 wt % Al₂O₃.

In at least one embodiment, the catalyst composition is 65 wt % (basedon the total weight of the catalyst system) of a 1:1 BF₃—MeOH complex ona Amberlyst or Amberlite support.

FIG. 1A is a flow diagram summarizing a method 100 of making a catalystsystem according to one embodiment. Method 100 includes providing anymetal oxide support material described herein at operation 105. At 110,the support material is calcined (or otherwise heated) at apredetermined temperature for a predetermined time as described above.Alternately, the support material is calcined (or otherwise heated) whenfirst manufactured and/or recalcined (or reheated) as received. Method100 includes forming the catalyst system by adding to the supportmaterial (a) a mixture comprising a Lewis acid (for example, BF₃), (b) amixture comprising a Lewis acid (for example, BF₃) and a complexingagent, or (c) both at operation 115. The complexing agent may be anycomplexing agent described herein, and may be used in excess. Thecatalyst system obtained is a solid.

FIG. 1B is a flow diagram summarizing a method 150 of making a catalystsystem according to another embodiment. Method 150 includes providingany ion exchange resin support material described herein at operation155. Method 150 also includes dehydrating (or otherwise heating) thesupport material at a predetermined temperature for a predetermined timeat operation 160 as described above. Alternately, the support materialis dehydrated (or otherwise heated) when first manufactured and/orre-dehydrated (or reheated) as received.

Method 150 includes forming the catalyst system by adding to the supportmaterial (a) a mixture comprising a Lewis acid (for example, BF₃), (b) amixture comprising a Lewis acid (for example, BF₃) and a complexingagent, or (c) both at operation 165. The complexing agent may be anycomplexing agent described herein, and may be used in excess. Thecatalyst system obtained is a solid.

In some embodiments, addition of the mixture comprising a Lewis acidincludes adding BF₃ gas uncomplexed with any complexing agent (asdescribed herein). In such embodiments, the support material may becontacted with excess BF₃ gas in a stainless steel cylinder at apressure of greater than about 0 psig (0 kPa), for example, betweenabout 35 psig (about 250 kPa) and about 500 psig (about 3500 kPa), forabout 4 hours. The cylinder is then vented and excess BF₃ is ventedthrough a caustic scrubber.

Alternately, the catalyst complex (e.g., the Lewis acid and complexingagent) is added to the support material. In such cases, addition of themixture comprising a Lewis acid and a complexing agent includespreforming the BF₃/complexing agent (the catalyst complex).

In some cases, the support material is slurried in a solvent duringcontact with the catalyst complex. Examples of solvents includenon-coordinating, non-oxygenate, non-reactive solvents includingnon-polar or weakly polar solvents, such as alkanes (for example,isopentane, hexane, n-heptane, octane, nonane, decane, undecane,dodecane, tridecane, tetradecane, pentadecane, hexadecane, and higheralkanes), although a variety of other materials including cycloalkanes,such as cyclohexane. Alternately, halogenated hydrocarbons can be usedas a solvent, such as carbon tetrachloride (CCl₄) and1,2-dichloroethane.

During addition of the catalyst complex to the support material, thetemperature of the mixture of the catalyst complex and the supportmaterial is maintained between about 0° C. and about 70° C. (forexample, between about 10° C. and about 60° C., such as between about10° C. and about 50° C., or at about room temperature). The reactionmixture is stirred while maintaining the temperature. Contact time,which may be the same as, or may include, the stirring time, istypically greater than about 0.1 hours (for example, between about 0.5hours and about 24 hours, such as between about 2 hours and about 16hours, or between about 4 hours and about 8 hours).

The solid catalyst systems can be prepared by any means in which thesupport materials can be contacted with BF₃ gas and/or BF₃ catalystcomplexes while maintaining the complexing temperature with the supportmaterials as described above. The complexing reaction can be exothermic,and the reaction of the catalyst and/or catalyst complex with thesupport material should be controlled to avoid loss of BF₃. Loss of BF₃may occur by breaking of the BF₃ complex bonds with the substrate,liberating BF₃ gas which is then, at the higher temperatures, lost fromthe solid substrate. The catalyst and/or catalyst complex may be addedby any mechanical means that allows sufficient mixing of the catalystand/or catalyst complex with the support material. In at least oneembodiment, the support material is placed in a rotating double conemixer and the catalyst complex is added ratably such that thetemperature is controlled within the desired range, e.g., not exceeding50° C.-60° C.

In at least one embodiment, a tube-in-shell heat exchanger in which thesupport material is packed in the tubes and the cooling media ismaintained on the jacket is used. In some embodiments, BF₃ gas and/orBF₃ catalyst complexes can be passed over the support material in thetubes until a maximum absorption, but less than excess, is obtained asevidenced by BF₃ or of the BF₃ catalyst complex exiting the tubes. Ifless than a maximum absorption is desired, the catalyst system can beback-blended with uncomplexed support material to the desired BF₃concentration.

FIG. 1C is a flow diagram summarizing a method 170 of preparing acatalyst system according to another embodiment. In the method 170, thecatalyst system can be further modified by contacting the solid catalystsystem with suitable modifying agents, for example, the oxygencontaining and nitrogen containing complexing agents described above.Such embodiments allow for the catalytic properties of the catalystsystem(s) to be adjusted, for example, with respect to formation ofalpha-vinylidene olefin isomers. Method 170 includes providing anysupport material described herein (metal oxide or organic support, e.g.,ion exchange resin) described herein at operation 175. Method 170includes calcining or dehydrating (or otherwise heating) the supportmaterial at a predetermined temperature for a predetermined time atoperation 180 as described above. Alternately, the support material isdehydrated (or otherwise heated) when first manufactured and/orre-dehydrated (or reheated) as received. Operation 180 is dependent onthe type of support material. Method 170 includes forming a firstcatalyst system by adding to the support material (a) a mixturecomprising a Lewis acid (for example, BF₃), (b) a mixture comprising aLewis acid (for example, BF₃) and a complexing agent, or (c) both atoperation 185. The complexing agent may be any complexing agentdescribed herein. The first catalyst system obtained is a solid. Method170 includes forming a second catalyst system by contacting the firstcatalyst system with one or more modifying agents.

In some embodiments, the modifying agents can be added to the catalystduring the catalyst manufacturing step. Alternately, the modifyingagents can be added to the feed during the polymerization step tofurther fine tune the catalyst properties such as selectivity to formHR-PIB. Thus, there are various methods of preparing the catalystsystem. In some embodiments, BF₃ gas is added to the support material.Alternately, BF₃-complexing agent is added to the support material. Inother embodiments, BF₃ gas is added to the support material and thencomplexing agent is added to the support material. In some embodiments,BF₃-complexing agent is added to the support material, and thenmodifying agents can be added to the support material. In otherembodiments, BF₃ gas is added to the support material, then complexingagent is added to the support material, and a modifying agent isadditionally added to the isobutylene feed. In some embodiments,BF₃-complexing agent is added to the support material, then modifyingagents can be added to the support material, and a modifying agent isadditionally added to isobutylene feed.

For example, the solid BF₃ complex is contacted with the modifying agentin a stirred or otherwise agitated vessel such as a rotating drum inwhich the modifying agent is sprayed onto the solid BF₃ complex andsubsequently absorbed. The temperature should be maintained at less thanabout 50° C. by controlling the spray rate, or by cooling (for examplewith internal cooling coils or with an external jacket or both). Thepressure should be greater than about 0 psig for example between about35 and about 500 psig with pressure provided by a nitrogen pad. Once theprescribed amount of modifying agent has been added, the mixture ismixed for about an additional 4 hours after which time the mixing vesselis vented to atmospheric pressure and the thus formed catalystdischarged to storage containers. The containers are preferably paddedwith about 1 psig to about 5 psig of nitrogen. The amount of modifyingagent is greater than about 0.5:1 mole ratio of modifying agent to BF₃(such as a mole ratio between about 1:1 and about 2:1, for examplebetween about 1:1 and about 1.4:1).

Suitable Polymer Precursor Feedstocks

The polymerization processes described herein utilize one or morepolymer precursors as input to the catalyst system, or to be contactedwith a catalyst system to form one or more polymer compositions. Thepolymer compositions (described in more detail below) include polymersmade from one or more polymer precursors. Polymer compositions mayinclude homopolymers, copolymers, or both. Polymer precursors suitablefor both the processes and polymer compositions described herein aredescribed in greater detail in the following.

Processes according to particular embodiments produce polymercompositions (for example, polyisobutylene including alpha vinylidenes,beta vinylidenes, and internal vinylidenes). For instance, in certainprocess embodiments, polymer precursors are contacted with the catalystsystem. Each of the polymer precursors used in processes (and/orincluded in polymer compositions) herein is from a feedstock, forexample, a liquid feedstock.

In some embodiments, the feedstock comprises about 1 wt % isobutylene(for example, greater than about 3 wt %, such as greater than about 5 wt%, greater than about 10 wt %, greater than about 15 wt %, greater thanabout 20 wt %, greater than about 25 wt %, greater than about 30 wt %,greater than about 35 wt %, greater than about 40 wt %, greater thanabout 45 wt %, greater than about 50 wt %, greater than about 55 wt %,greater than about 60 wt %, greater than about 65 wt %, greater thanabout 70 wt %, greater than about 75 wt %, greater than about 80 wt %,greater than about 85 wt %, greater than about 90 wt %, greater thanabout 95 wt %, greater than about 99 wt %, or greater than about 99.99wt %) based on a total weight of the feedstock. Alternately, thefeedstock consists essentially of isobutylene.

In some embodiments, the feedstock comprises other butylenes and/orunreactive compounds including alkanes and isoalkanes, such as C₂ to C₄₀alkanes and isoalkanes.

In some embodiments, the feedstock comprises isobutylene. Examplefeedstocks include raffinate-1, also known as raff-1, or C₄ raffinate.The actual composition of raffinate-1 is variable depending on thesource. A typical raffinate-1 feedstock might contain about 0.5 wt % C₃,about 4.5 wt % isobutane, about 16.5 wt % n-butane, about 38.5 wt %1-butene, about 28.3 wt % isobutylene, about 10.2 wt % cis- andtrans-2-butene, and less than about 0.5 wt % butadiene, and less thanabout 1.0 wt % oxygenates. Other examples of raffinate-1 feedstocks alsoinclude those provided in Table 2.

TABLE 2 Examples of Raffinate-1 Feedstocks Composition Ex. 1 Ex. 2 Ex. 3Ex. 4 C₃ (wt %) 0.5 — 4.0 0.6 isobutane (wt %) 4.5 14.0 25.0 4.4n-butane (wt %) 16.5 7.0 13.0 16.7 1-butene (wt %) 38.5 45.0 15.0 30.0isobutylene (wt %) 28.3 22.0 15.0 37.2 cis-2-butene (wt %) 10.2 (totalof cis 6.7 15.5 2.3 trans-2-butene (wt %) and trans isomers) 5.0 12.08.4 butadiene (wt %) 0.5 0.3 0.5 0.4 Amounts provided are approximatevalues.

The presence of oxygenates may affect the catalytic reaction. Somecommon oxygenates found in typical feedstocks; methanol, ethanol,dimethyl ether, diethyl ether, t-butanol, MTBE. While not wishing to bebound by theory, it is believed that oxygenates have a twofold impact onisobutylene polymerization: oxygenates can act as initiators forpolymerization and thus can reduce molecular weight and broadenmolecular weight distribution, and oxygenates can complex with the BF₃catalyst possibly resulting in complexes that can yield undesirable PIBolefin isomers and the further complexing can reduce the activity of thecatalyst.

The C₃ and the n-butane are unreactive and pass through the reactorunchanged and are removed from the reaction mixture in the downstreamstripping steps. Reaction of isobutylene depends on various factorsincluding reaction conditions, and thus adjusting conditions can allowfor varied final products. The 1- and 2-butenes may react to varyingdegrees depending on the catalyst type and reactor conditions. Theunreacted olefins may also be removed from the polymer product in thedownstream stripping steps.

Another feedstock that can be used is the effluent from adehydrogenation of isobutane to isobutylene. Typically, such effluentscontain between about 42 wt % and about 45 wt % isobutylene, and betweenabout 50 wt % and about 52 wt % isobutane, with the balance being C₃,normal butanes, butylenes, and butadiene. This feedstock is particularlysuitable when unreactive isobutane may be utilized, for example, incooperation with an isobutane dehydrogenation unit.

In at least one embodiment, the feedstock comprises at least about 80 wt% isobutylene (for example, at least about 90 wt %, such as at leastabout 99 wt %) with the balance being isobutane and minor amounts of C₃,normal butanes, butylenes, and butadiene. This feedstock is alsosuitable for production of HR-PIB.

When using any feedstock, any unreacted polymer precursor may berecycled.

Copolymers may be formed if other olefins (i.e. other polymerizablecompounds) are present in the feedstock. Feedstocks comprising higheramounts of isobutylene as the olefin precursor more readily produceHR-PIB. However, feedstocks (such as raffinate streams, which have loweramounts of isobutylene) may be used. Raffinate streams contain, inaddition to isobutylene, other butylenes including 1-butene, and cis-and trans-2-butene. These butylene compounds can co-polymerize with theisobutylene to give butene segments in the polymer chain. These butylenecompounds are less reactive than isobutylene and therefore tend to endcap growing of the polymer chains and produce lower Mn polymers. Also,the end-capped chains tend not to be alpha vinylidene groups. Reactionconditions can be adjusted to selectively polymerize isobutylene andminimize the normal butene reactions, usually involving lowertemperatures reaction temperatures.

Polymerization Processes

As noted previously, embodiments of the present invention includepolymerization processes wherein polymer precursors are contacted with acatalyst system to form a polymer composition. The polymer compositionsinclude polyisobutylene (PIB), and in particular highly reactivepolyisobutylene (HR-PIB). For the polymerizations, BF₃ does not need tobe mixed with a complexing agent, as BF₃ on the support material iscapable of forming polymer compositions including PIB, and particularlyHR-PIB. In other embodiments, the catalyst is complexed with acomplexing agent and is capable of forming the same polymercompositions. Typically, use of a complexing agent helps produce PIBwith a high content of alpha vinylidene olefin isomer. While not wishingto be bound by theory, it is believed that complexing BF₃ mediates someof the acidity of BF₃ and reduces the rate of isomerization of initiallyformed alpha vinylidene isomers to more internally located and lessreactive isomers.

FIG. 2A is a flow diagram summarizing a method 200 of making a polymercomposition according to one embodiment. The method includes providing acatalyst system at operation 205. The catalyst system includes (a) anysupport material described herein (for example Group IIIA, Group IVA,and Group IVB metal oxides, and combinations thereof, such as Al₂O₃,ZrO₂, TiO₂, SnO₂, CeO₂, SiO₂, SiO₂/Al₂O₃, and combinations thereof); and(b) a Lewis acid (for example, BF₃). In some versions, the catalystsystem further comprises a complexing agent, including any complexingagent described herein.

The catalyst system can include (a) an organic support material (forexample an ion exchange resin, such as an anionic exchange resin, acationic exchanges resin (such as Amberlyst™ and Amberlite™ resins),and/or combinations thereof); and (b) a Lewis acid (for example, BF₃).In some embodiments, the catalyst system further comprises a complexingagent, including any complexing agent described herein.

In some embodiments, a catalyst system includes (a) a combination ofinorganic oxide (i.e., Al₂O₃, ZrO₂, TiO₂, SnO₂, CeO₂, SiO₂, SiO₂/Al₂O₃,and combinations thereof) and organic support (i.e., an ion exchangeresin, such as an anionic exchange resin, a cationic exchange resin, ora combination thereof); and (b) a Lewis acid (for example, BF₃). In someembodiments, the catalyst system further comprises a complexing agent,including any complexing agent described herein.

Method 200 further includes providing a feedstock comprising isobutyleneat operation 210. The feedstock can be a liquid feedstock. Any feedstockdescribed herein may be used.

Method 200 includes forming a reaction mixture comprising the feedstockand the catalyst system at operation 215, as described below. Method 200further includes contacting the isobutylene with the catalyst system atoperation 220 and obtaining a polymer composition at operation 225.Polymer compositions are described below. In some embodiments, formingthe reaction mixture comprising the feedstock and the catalyst systemcomprises flowing the catalyst system into a reactor and flowing thefeedstock into the reactor, and wherein contacting the isobutylene withthe catalyst system comprises maintaining a temperature of the reactionmixture at a predetermined temperature or range of temperatures.

It should be noted that one or more of the operations may occur beforeor after that shown in FIG. 2A or may occur simultaneously in someembodiments. For example, operation 205 may occur after operation 210.

FIG. 2B is a flow diagram summarizing a method 250 of making a polymercomposition according to another embodiment. The method 250 includesproviding a catalyst system at operation 255, and providing a feedstockcomprising isobutylene at operation 260. Operations 255 and 260 aredescribed above according to operations 205 and 210, respectively.

Method 250 further includes flowing the catalyst system into a reactorat operation 265 and flowing the feedstock comprising isobutylene intothe reactor at operation 270 as described below. In some cases, thecatalyst system is provided to the reactor as a slurry. The slurry maycomprise the catalyst system and one or more oligomeric byproductsand/or light polymers from PIB polymerization itself (for example, C₈ toC₁₆ oligomers, such as C₈ and/or C₁₂ PIB, and PIB having a molecularweight between about 350 Da and about 500 Da). In some embodiments, theslurry optionally comprises a non-polar carrier solvent such as alkanesfrom octane through hexadecane and higher alkanes.

Method 250 includes forming a reaction mixture comprising the feedstockand the catalyst system at operation 275, and includes maintaining atemperature of the reaction mixture at a predetermined temperaturerange, for example, between about −35° C. and about 100° C., atoperation 280.

Method 250 further includes contacting the isobutylene with the catalystsystem at operation 285, and obtaining a polymer composition atoperation 290. Polymer compositions are described below.

It should be noted that one or more of the operations may occur beforeor after that shown in FIG. 2B or may occur simultaneously in someembodiments. For example, operations 265 may occur after operation 270.

Methods of making compositions can include an optional operation ofcalcining the support material as described above. In some embodiments,methods of making compositions include forming the catalyst system byadding to the support material (a) a mixture comprising BF₃, (b) amixture comprising BF₃ and a complexing agent, or (c) both.

In some embodiments, suitable concentrations of the catalyst system inthe reaction mixture are greater than about 500 ppm based on a totalweight of the catalyst feed, wherein a BF₃ concentration in the reactionmixture is about 125 ppm based on the total weight of the catalyst feed.In at least one embodiment, the concentration of the catalyst system inthe reaction mixture is between about 500 ppm and about 10,000 ppm basedon a total weight of the catalyst feed, and wherein a BF₃ concentrationin the reaction mixture is between about 125 ppm and about 2,500 ppmbased on the total weight of the catalyst feed. Alternately, theconcentration of the catalyst system in the reaction mixture is betweenabout 1,000 ppm and about 5,000 ppm based on a total weight of thecatalyst feed, and wherein a BF₃ concentration in the reaction mixtureis between about 250 ppm and about 1,250 ppm based on the total weightof the catalyst feed.

Furthermore, although known polymerization techniques may be employed,processes according to certain embodiments utilize particular conditions(e.g., temperature and pressure). Temperatures generally may include atemperature of between about −35° C. to about 100° C., for example,between about 0° C. and about 70° C. ° C. Pressure may depend on thedesired scale of the polymerization system. For example, in somepolymerizations, pressure may generally be conducted at the autogenouspressure of the reaction mixture at the selected reaction temperature.In some embodiments, the pressure of the reactor is greater than about 0psig (about 0 kPa) (for example, between about 35 psig (about 250 kPa)and about 500 psig (about 3500 kPa), such as between about 35 psig(about 250 kPa) and about 500 psig (about 3500 kPa), between about 50psig (about 350 kPa) and about 300 psig (about 2100 kPa), or betweenabout 35 psig (about 250 kPa) and about 100 psig (and about 700 kPa)).Reaction pressure can depend on the type of reactor used. For continuousstirred tank reactors (CSTR) in which cooling is provided by ebullientcooling, that is by partial volatilization of the reaction mixture, thevolatilization temperature, and thus the reaction temperature, isdependent on reactor pressure. Lower pressure provides lowertemperatures, and for practical purposes, with the lower limit set bythe boiling point of the reaction mixture at ambient pressure. In thecase of butylenes, this is around about −5° C. to about −10° C. In casesrequiring lower temperatures, other inerts are added with lower boilingpoints, such as propane. In loop reactors or CSTR not using ebullientcooling reaction pressure is not an issue as long as the reactionmixture is maintained in the liquid phase. For PIB this is typicallygreater than about 0 psig (about 0 kPa), for example greater than about35 psig (about 250 kPa).

In the polymerization processes described herein, the run time of thereaction is up to about 600 minutes (for example, up to about 300minutes, such as between about 1 minute and about 250 minutes, betweenabout 1 minute to about 150 minutes, or between about 1 to about 120minutes).

Heterogeneous BF₃ catalyst system processes of the present disclosureare also characterized by reaction times of less than about 4 minutes(for example, less than about 3 minutes, less than about 2 minutes, orless than about 1 minute).

Times and temperatures are controlled such that no significant olefinisomerization occurs during polymerization and conversion and molecularweights are in desirable ranges. Reaction temperatures and pressures,and polymer precursor concentrations can be selected to control for theMn of the polymer composition. For example, higher temperaturestypically provide polymer compositions with higher Mn.

Temperature control in the reactor is obtained by offsetting the heat ofpolymerization with reactor cooling by using reactor jackets or coolingcoils to cool the contents of the reactor, auto refrigeration,pre-chilled feeds, vaporization of liquid medium (diluent, polymerprecursors, or solvent) or combinations of all three. In the case ofCSTR with ebullient cooling, the boiling mixture is cooled with achilled overhead condenser. For non-ebullient cooled CSTR any type ofheat exchanger could be used to chill the reactor jacket using anysuitable cooling media. In some embodiments, a fast reactor is used. Afast reactor is one in which the reactor is the heat exchanger with thereaction taking place in the tubes with cooling on the shell. Any typeof suitable cooling media can be used depending mainly on operatingtemperature range. Adiabatic reactors with pre-chilled feeds may also beused. In some embodiments, the reactor(s) is operated in as much of anisothermal mode as possible. Non-isothermal reactor operation results inbroader molecular weight distributions. In series operation, the secondreactor temperature is higher than the first reactor temperature. Inparallel reactor operation, the temperatures of the two reactors areindependent.

Suitable reactors for the polymerization include batch, continuousstirred tank reactor (CSTR), plug flow, fluidized bed, immobilized bed,and fixed bed. More than one reactor may be operated in series orparallel. These reactors may have or may not have internal cooling orheating, and the feeds may or may not be refrigerated.

CSTR

In some embodiments, and for CSTR, the catalyst system is slurried withone or more oligomeric byproducts and/or light polymers from PIBpolymerization itself (for example, C₈ to C₁₆ oligomers, such as C₈and/or C₁₂ PIB, and PIB having a molecular weight between about 350 Daand about 500 Da), at about a 10 wt % concentration. The catalyst systemslurry is then injected into the incoming feed stream. In someembodiments, the catalyst system slurry is injected into the incomingfeed stream at a point where the physical distance between the injectionpoint in the feed line and the point at which the feed enters thereactor is at a minimum. In some embodiments, the injection point forthe catalyst may be on the suction side of the feed pump to providemixing. In some embodiments, the slurry optionally comprises a non-polarcarrier solvent such as alkanes from octane through hexadecane andhigher alkanes. In some embodiments, the concentration of the catalystsystem in the reaction mixture for CSTR is between about 1,000 ppm andabout 2,000 ppm based on a total weight of the catalyst feed, wherein aBF₃ concentration is between about 250 ppm and about 500 ppm based onthe total weight of the feed. Residence times are on the order of lessthan about 600 minutes (for example, about 120 minutes, such as lessthan about 60 minutes, or between about 30 minutes to about 60 minutes)and can be controlled by catalyst system concentration. Higher catalystsystem concentrations, up to a point, increase the reaction rate. Thepolymerization reaction is highly exothermic and a limiting factor toreaction rate is the ability to remove the heat of reaction.

In conventional plants that utilize CSTR, the reaction mixturecomprising the catalyst system is flowing upward in the reactor, throughat least a first portion and a second portion. The first portion of thereactor is relatively narrow to provide higher velocity and highercatalyst system mixing. The second portion of the reactor is wider toprovide lower velocity and less catalyst system mixing, allowing forsome settling of the catalyst system back into the reaction zone. Thecrude reaction mixture exits near the top of the reactor with somecatalyst system being carried out with the exiting crude reactionmixture. The catalyst system exiting the reactor is made up with thecatalyst system injection such that a constant catalyst system amount ismaintained in the reactor. The reaction temperature can be maintained byvaporization of a portion of the isobutylene containing feed controlledby the reactor pressure; higher reactor pressure gives higher reactiontemperature according to the vapor pressure curve of the systembutylenes. Mn of the polymer is controlled by reaction temperature withhigher reaction temperature giving lower Mn. Reaction temperaturesbetween about −5° C. and about 5° C. provide polymers having an Mn ofabout 2,300 daltons. Reaction temperatures between about 18° C. andabout 22° C. provide polymers having an Mn of about 1,000 daltons. Thecrude reaction mixture leaving the reactor is treated with aqueouscaustic streams to quench and wash out the catalyst system.

Alternately, these plants can be modified to include a catalyst systemfiltration (or other solid-liquid separation devices as described below)to remove the catalyst system thereby eliminating the water washingoperations and the need to dispose of waste water containing catalystsystem residues. Optionally, a water washing operation may be performeddepending on application or type of plant. Removal of the catalystsystem also allows for recycling of the catalyst system. The plants canalso include one or more distillation columns as described below. Anystandard Cosden type polymerization units (such as CSTR plants usingebullient cooling) can employ the technology described in thisdisclosure. Other plants can be used such CSTR plants without ebullientcooling and tubular reactor plants.

Tubular Loop Reactors

In some embodiments, and for fast reactor modes, the reactor is atube-in-shell heat exchanger with the reaction taking place in the tubesand cooling provided through the shell side of the heat exchanger withthe heat of reaction taken out by an external chiller unit.

One reactor design is a two-pass heat exchanger. Using a slurriedcatalyst system, the reaction is carried out in the liquid phase atpressures of at least about autogenous pressures, typically greater thanabout 0 psig (0 kPa) (for example, between about 35 psig (about 250 kPa)and about 300 psig (about 2100 kPa), between about 50 psig (about 345kPa) and about 300 psig (about 2100 kPa), or between about 100 psig(about 700 kPa) and about 150 psig (about 1000 kPa)).

In some embodiments, a tubular loop reactor is used. In suchembodiments, the circulation loop is provided to deliver high velocityin the tubes at a Reynold's number of the circulating liquid in thetubes greater than about 2,000. In some embodiments the residence timein the reactor is less than about 120 minutes (for example, less thanabout 90 minutes, less than about 60 minutes, less than about 30minutes, less than about 10 minutes, less than about 4 minutes, lessthan about 3 minutes, less than about 2 minutes, or less than about 1minute; alternately, between about 30 seconds and about 4 minutes).Reynolds numbers greater than about 2,000 allow for turbulent flow inthe tubes which increases the heat exchange and the ability to removethe heat of reaction in very short periods of time. The ability toquickly remove the heat of reaction allows for operation at very shortresidence times. The concentration of the catalyst system in thereaction mixture is between about 500 ppm and about 10,000 ppm based ona total weight of the catalyst feed, and wherein a BF₃ concentration inthe reaction mixture is between about 125 ppm and about 2,500 ppm basedon the total weight of the catalyst feed. In some embodiments, theconcentration of the catalyst system in the reaction mixture is betweenabout 1,000 ppm and about 5,000 ppm based on a total weight of thecatalyst feed, and wherein the BF₃ concentration in the reaction mixtureis between about 250 ppm and about 1,250 ppm based on the total weightof the catalyst feed. Alternately, the concentration of the catalystsystem in the reaction mixture is greater than about 2,000 ppm based ona total weight of the catalyst feed, and wherein the BF₃ concentrationis greater than about 500 ppm based on the total weight of the catalystfeed.

In some embodiments, the reactor system is a tubular loop reactor inwhich the Reynold's number of the circulating liquid in the tubes isgreater than about 2,000 and the residence time in the reactor is lessthan about 120 minutes (for example, less than about 90 minutes, lessthan about 60 minutes, less than about 30 minutes, less than about 10minutes, less than about 4 minutes, less than about 3 minutes, less thanabout 2 minutes, or less than about 1 minute; alternately, between about30 seconds and about 4 minutes) such that the solid catalyst system isimmobilized in the tubes by attaching the catalyst system particles to asuitable substrate. Because the catalyst system is constrained in thetubes, no post reaction recovery is required. Suitable substratecompositions and geometries for attaching the solid BF₃ catalyst systemparticles can include ceramic mats such as those sold by NGK Insulatorsfor use in modern catalytic convertors, or wire mesh or wire fibers. Assuch, the catalyst system particles (or catalyst complex) can be used infixed bed reactors to produce HR-PIB. The solid catalyst systems of thepresent disclosure can be further attached or otherwise immobilized toother solid substrates chemically, physically, or mechanically means, ora combination thereof.

For tubular loop reactors, the catalyst system is slurried with one ormore oligomeric byproducts and/or light polymers from PIB polymerizationitself (for example, C₈ to C₁₆ oligomers, such as C₈ and/or C₁₂ PIB, andPIB having a molecular weight between about 350 Da and about 500 Da), atabout 10 wt % catalyst system concentration. The catalyst system slurryis then injected into the incoming feed stream. In some embodiments, thecatalyst system slurry is injected into the incoming feed stream at apoint where the physical distance between the injection point in thefeed line and the point at which the feed enters the reactor is at aminimum. In some embodiments, the injection point for the catalyst maybe on the suction side of the feed pump to provide mixing. In someembodiments, the slurry optionally comprises a non-polar carrier solventsuch as alkanes from octane through hexadecane and higher alkanes.

After the reaction effluent leaves (or is discharged from) the CSTR,tubular loop, or other reactors, the reaction effluent may be purifiedby separation, atmospheric stripping, vacuum stripping, or a combinationthereof to remove byproducts, unreactive compounds, catalyst residues,and unreacted polymer precursors. Unreacted polymer precursors may berecycled. For example, such purification may be accomplished in a plantby passing the crude polymer composition through a solid-liquidseparation device and then through a pressure distillation column toremove the unreacted polymer precursors and other non-reacted residues.The distillation columns may be atmospheric and/or vacuum distillationcolumns.

Passing the crude polymer compositions through a solid-liquid separationdevice serves to separate solid catalyst system particles, unreactedresidues, and other solids from the crude polymer compositions.Distilling serves to separate dimers, oligomers, unreacted polymerprecursors, unreactive compounds, and other non-reacted residues fromthe polyisobutylene polymer composition.

Accordingly, and in some embodiments, the method of making a polymercomposition includes discharging the polymer composition from thereactor; feeding the polymer composition one or more suitable separationapparatuses (for example one or more of a suitable solid-liquidseparation devices (such as filters, centrifugation devices, and cycloneseparation devices), and one or more of a distillation devices (e.g.,distillation columns)); and discharging the polymer composition from theone or more separation apparatuses. Any of those operations may berepeated one or more times.

In the distilling operation, the crude polyisobutylene polymer istreated in a distillation column to remove unwanted species. Thedistilling operation can include passing the crude polyisobutylenepolymer composition to a first distillation column, feeding the crudepolyisobutylene polymer composition under pressure in the firstdistillation column so as to remove unreacted polymer precursors (e.g.,isobutylene) and unreactive compounds (e.g., isobutane and isobutylene)from the crude polyisobutylene polymer composition, and discharging thepolyisobutylene polymer composition from the first distillation column.The distilling operation may further include passing the dischargedpolyisobutylene polymer composition from the first distillation columnto a second distillation column, feeding the polyisobutylene polymercomposition in the second distillation column at atmospheric pressure soas to remove C₈ (dimer) byproducts from the polyisobutylene polymercomposition, and discharging the polyisobutylene polymer compositionfrom the second distillation column. The distilling operation mayfurther include passing the discharged polyisobutylene polymercomposition from the second distillation column to a third distillationcolumn, feeding the polyisobutylene polymer composition in the thirddistillation column under vacuum conditions so as to remove higheroligomer byproducts (e.g., C₁₂ and C₁₆) from the polyisobutylene polymercomposition, and discharging the polyisobutylene polymer compositionfrom the third distillation column. Any of those operations may berepeated one or more times.

Each of the various polymerization processes described herein can becarried out using general polymerization techniques known in the art.Any suspension, homogeneous, bulk, slurry, solution slurry, or gas phasepolymerization process known in the art can be used. Such processes canbe run in a batch, semi-batch, or continuous mode. In some embodiments,homogeneous polymerization processes and slurry processes are used. Ahomogeneous polymerization process is defined to be a process where atleast about 90 wt % of the product is soluble in the reaction media. Abulk process is defined to be a process where polymer precursors itselfare used as the reaction medium and the concentration of polymerprecursors in all feeds to the reactor is about 70 vol % or more.Alternately, no solvent or diluent is present or added in the reactionmedium, (except for the small amounts used as the carrier for thecatalyst system or other additives, or amounts typically found with thepolymer precursors). In another embodiment, the process is a slurryprocess. In the slurry process, a suspension of supported catalyst isemployed and polymer precursors are polymerized on the catalystparticles and/or catalyst systems.

In some slurry process embodiments, the suspension includes diluent. Thesuspension can be intermittently or continuously removed from thereactor where the volatile components are separated from the polymer andrecycled, optionally after a distillation, to the reactor.

In some embodiments, the polymerization is conducted in an aliphatichydrocarbon solvent (e.g., isobutane, butane, pentane, isopentane,hexanes, isohexane, heptane, octane, dodecane, and mixtures thereof, andthe like). Other additives may also be used in the polymerization, asdesired, such as one or more scavengers, promoters, modifiers, reducingagents, and oxidizing agents.

Polymer Compositions

The polymerization processes described herein produce polymercompositions. In some embodiments, the polymer compositions arepolyisobutylenes having one or more of the following properties:

1) A number average molecular weight, Mn, of greater than about 320daltons (for example between about 320 daltons and about 10,000 daltons,such as between about 320 daltons and about 5,000 daltons, or betweenabout 320 daltons and about 2,500 daltons, such as about 350 daltons,about 700 daltons, about 950 daltons, about 1300 daltons, or about 2,250daltons).

2) the polyisobutylene comprises a first portion comprising polymerchains having alpha vinylidene groups, and one or more of a secondportion comprising polymer chains having beta vinylidene groups and athird portion comprising polymer chains having internal vinylidenegroups, wherein: the first portion is greater than about 75 wt % (forexample, greater than about 80 wt %, such as greater than about 82 wt %,greater than about 85 wt %, greater than about 87 wt %, greater thanabout 90 wt %, greater than about 92 wt %, greater than about 94 wt %,or greater than about 95 wt %) based on a total weight of thecomposition, and a total content of the second portion plus the thirdportion is less than about 25 wt % (less than about 20 wt %, less thanabout 18 wt %, less than about 15 wt %, less than about 13 wt %, lessthan about 10 wt %, less than about 8 wt %, less than about 6 wt %, orless than about 5 wt) based on the total weight of the composition.

3) A polydispersity index (PDI), which is the ratio of Mw/Mn, of lessthan about 5 (for example, less than about 2.5, less than about 2, lessthan about 1.5, or less than about 1.3).

In addition to isobutylene olefin isomers, by-products of thepolymerization can include C₈-C₁₆ by-products, for example, dimers (C₈)and oligomers (C₁₂-C₁₆). Copolymers may also be produced if other olefinprecursors are present in the feedstock. Feedstocks comprising higheramounts of isobutylene as the polymer precursor more readily produceHR-PIB. However, feedstocks (such as raffinate streams, which have loweramounts of isobutylene) may be used. Raffinate streams contain, inaddition to isobutylene, other butylenes including 1-butene, and cis-and trans-2-butene. These butylene compounds can co-polymerize with theisobutylene to give butene segments in the polymer chain. These butylenecompounds are less reactive than isobutylene and therefore tend to endcap growing of the polymer chains and produce lower Mn polymers. Inaddition, the end-capped chains tend not to be alpha vinylidene groups.Reaction conditions can be adjusted to selectively polymerizeisobutylene and minimize the normal butene reactions, usually involvinglower temperatures reaction temperatures.

Applications

Any of the foregoing polymers, including compounds thereof, may be usedin a variety of end-use applications, including any application suitablefor PB, PIB, and HR-PIB. Examples of applications for HR-PIB includesubsequent derivatization reactions to produce fuel and lubricantadditives. Examples of applications for PIB and HR-PIB includeadhesives, sealants, lubricants & greases, metal working, cosmetics, andmining.

Test Methods

Polymer Compositions. The type and amount of each olefin isomer (i.e.,alpha vinylidene, beta vinylidene, and other isomers) is determined by¹³C NMR.

¹³C NMR spectra were collected using a 500 MHz Bruker pulsed fouriertransform NMR spectrometer equipped with a 10 mm Broad Band Observation(BBO) probe at about room temperature. The polymer sample is dissolvedin chloroform-d (CDC₁₃) and transferred into a 10 mm glass NMR tube.Typical acquisition parameters are inverse-gated (IG) decoupling, a 90°pulse, and a 40 second relaxation delay. Chemical shifts are determinedrelative to the CDCl₃ signal which is set to about 77.2 ppm. To achievemaximum signal-to-noise for quantitative analysis, multiple data filesmay be added together. The spectral width was adjusted to include all ofthe NMR resonances of interest. ¹³C NMR shifts for the olefin carbonatoms are provided below in Table 3.

TABLE 3 NMR Data and Weight Percent of Polymer Compositions WeightChemical Shifts (ppm) Percent Olefin Isomer (¹³C NMR (CDCl₃)) (wt %)alpha vinylidene 143 (RC(CH₃)═CH₂); >80 isomer 115 (RC(CH₃)═CH₂)terminal beta 136 (RC(H)═C(CH₃)₂); <10-15 vinylidene isomer 128(RC(H)═C(CH₃)₂) terminal trisubstituted 134 (RC(CH₃)═CH(CH₃)); <1vinylidene isomer (1) 123 (RC(CH₃)═CH(CH₃)) terminal trisubstituted 139(RC(H)═C(CH₃)(CH₂CH₃)); <2-5% vinylidene isomer (2) 130(RC(H)═C(CH₃)(CH₂CH₃) terminal 133 (RC(CH₃)═C(CH₃)₂); <2-5%tetrasubstituted 122 (RC(CH₃)═C(CH₃)₂) vinylidene isomer internaldisubstituted (RC(═CH₂)(CH₃)); <2-5% vinylidene isomer 116(RC(═CH₂)(CH₃)) All data is provided in approximate values.

Polymer molecular weight: Molecular weights (weight-average molecularweight, Mw, number-average Molecular weight, Mn) and PDI (ratio ofMw/Mn) are determined using gel permeation chromatography (GPC).Equipment includes a Waters Alliance 2695 HPLC system with adifferential refractive index detector (DRI). A typical GPC procedure isto dissolve the sample to be tested in tetrahydrofuran (THF) at aconcentration of about 1 wt % to about 10 wt %. The polymer solution ispumped through a series of columns packed with Styragel™ beads of knownporosity. Typical pore diameters range from about 10,000 Å down to about50-100 Å, and a typical column string includes a 10⁴ Å column, a 10³ Åcolumn, a 1000 Å column and an about 2-100 Å columns. For example,Waters Styragel™ HR columns 1, 3, and 4 can be used. The nominal flowrate is about 1.0 ml/min. The various transfer lines, columns anddifferential refractometer (the DRI detector) are contained in an ovenmaintained at about 40° C. Elution solvent is THF. There is a 105-samplecarousel for automatic injections. Empower 2 is the software system forcontrolling the separation and analysis.

The columns are calibrated with known molecular weight standards, bothnarrow distribution standards and broad distribution standards (forexample, polystyrene standards from a molecular weight of 500 to 400K).From the calibration, Mn and Mw can be determined for a polymer sample.PDI is the ratio of Mw/Mn.

Polymer solutions for GPC are prepared by placing the dry polymer in aglass container, adding the desired amount of THF, and then filteringthe mixture through a 0.45-micron nylon or PTFE filter. All quantitiesare measured gravimetrically. The concentration of polymer to THF isabout 10 to 20 mg/ml

Prior to running each sample the DRI detector and the injector arepurged. Flow rate in the apparatus is then increased to about 0.5ml/minute, and the DRI is allowed to stabilize for about 8 hours toabout 9 hours before injecting the first sample. Each sample run takesabout one hour to complete.

EXAMPLES

The present disclosure, while not meant to be limited by, may be betterunderstood by reference to the following examples and tables.

Catalyst System Examples 1-6: Calcination of support material andaddition of Lewis acid to gamma-alumina support material. Gamma-aluminabeads (γ-alumina spheres) were calcined for about 2 hours at varioustemperatures (i.e., about 25° C., about 250° C., about 400° C., about550° C., about 700° C., and about 900° C.). The beads were treated withan excess of BF₃ gas in a stainless-steel cylinder at a pressure ofabout 35 psig (about 250 kPa) for about 4 hours to form catalyst systemexamples 1-6. The cylinder was then vented and any remaining excess BF₃was vented through a caustic scrubber. The active amount of BF₃ gasabsorbed by the support material was determined gravimetrically.

The data are summarized in Table 4 and show that the concentration ofBF₃ on the alumina at calcination temperatures below about 250° C. isabout 16 wt % BF₃. As the calcination temperature is increased aboveabout 400° C., the concentration of BF₃ on the alumina increased tobetween about 23 wt % and about 24 wt % and remained about constant upto about 700° C. Calcination temperatures for these gamma alumina beadsare, for example, between about 400° C. and about 900° C., such as,between about 550° C. to about 700° C. Gamma-alumina support materialcalcination temperatures above about 700° C. can result in sintering ofthe gamma-alumina support material resulting in decreased surface area.

TABLE 4 BF₃ Capacity on Gamma-Alumina As a Function of CalcinationTemperature Catalyst System Calcination Temperature BF₃ Example (° C.)(g) (wt %) 1 25 16.3 2 250 15.4 3 400 22.3 4 550 23.6 5 700 23.5 6 90023.5

Polymer Composition Example 1: Polymerization of isobutylene to makeHR-PIB using the BF₃ on gamma-alumina catalyst system. A total weight ofabout 63 g of high purity isobutylene (HPIB) containing greater than99.9 wt % isobutylene was charged to a 500 ml pressure bottle and cooledusing an ice/salt bath to a temperature of about −5° C. About 0.4 grams,6,400 ppm, of BF₃ on alumina beads (at about 23.5 wt % active BF₃) wasadded to the isobutylene reaction mixture with stirring. Stirring wasmaintained during the course of the reaction. After about 40 minutes,the reaction was quenched by decanting the mixture while still cold toremove the catalyst beads. Optionally, the crude mixtures may be washedwith water. The reaction mixture was then heated at about 75° C. forabout 2 hours to remove unreacted isobutylene. Gravimetric analysisshowed conversion to HR-PIB was about 76%. This crude, unstripped samplewas analyzed by ¹³C NMR and found to contain about 72 wt % alphavinylidene olefin isomer with a molecular weight (Mn) of about 608daltons. Conversion is the amount of HPIB converted to dimers, oligomersand HR-PIB, and selectivity is the amount of converted isobutylene thatis HR-PIB product, excluding dimers and oligomers.

The crude, unstripped sample (about 25 g) was then charged to a 50 mlboiling flask and stripped using a distillation column at a temperaturesetting of about 150° C. for about 1 hour, then at a setting of about175° C. for about 1 hour and then at a setting of about 200° C. forabout 1 hour. The maximum internal temperature reached was about 183° C.The final stripped sample was analyzed by ¹³C NMR and found to containabout 82 wt % alpha vinylidene olefin isomer with a Mn of about 900daltons. Gravimetric analysis of the final stripped sample indicated theselectivity to HR-PIB to be 79 wt %.

Stripping removed some light oligomers that had olefin isomercompositions other than contained in the actual HR-PIB polymer. Removalof the oligomer products of low Mn further had the effect of increasingthe average product Mn. An Mn increase on stripping is due to removal oflow Mn by-products. The concomitant increase in alpha vinylidene amountis also due to removal of by-products which, themselves are notparticularly high in alpha vinylidene.

Catalyst System Examples 7-8: Calcination of support material andaddition of Lewis acid/complexing agent to the silica-alumina supportmaterial. Silica-alumina support materials containing various ratios ofSiO₂/Al₂O₃ were calcined at about 700° C. for a time greater than about4 hours. Catalyst complex (BF₃—MeOH (1:1)) was added to the supportmaterials to form catalyst system examples 7 and 8. BF₃—MeOH catalystcomplexes are passed over the support material until a maximumabsorption, but less than excess, is obtained as evidenced by theBF₃—MeOH catalyst complex exiting the tubes.

During addition of the catalyst complex to the support material, themixture of the catalyst complex and the support material was maintainedat temperatures between about 10° C. and about 60° C. with heating orcooling as required. The reaction time was about 4 hours. Atube-in-shell heat exchanger was used for the reaction with thecomplexing reaction taking place in the tubes and heating or cooling asrequired on the shell side.

TABLE 5 BF₃—MeOH Capacity on Silica-Alumina Support Material As aFunction of Calcination Temperature Catalyst Silica-Alumina CalcinationBF₃-MeOH System Support Material Temperature Capacity Example (wt %Al₂O₃) (° C.) (wt %) 7 about 50 wt % Al₂O₃ 700 65 8 about 25 wt % Al₂O₃700 72

Table 5 shows the BF₃—MeOH capacity of two silica-alumina supportmaterials having two different ratios of SiO₂/Al₂O₃ with differentporosities. The SiO₂/Al₂O₃ support material having about 75 wt % SiO₂had the higher porosity and had the higher capacity for BF₃—MeOHcomplex. While not wishing to be bound by theory, it is believed thatthis result indicates that at least some of the BF₃ complex is absorbedin the pores of the substrate due to the higher pore volume ofSiO₂/Al₂O₃ support material having about 75 wt % SiO₂.

Polymer Composition Example 2: Polymerization of isobutylene to makeHR-PIB using catalyst system example 7 (BF₃—MeOH (1:1) catalyst complexon SiO₂/Al₂O₃ support material having about 50 wt % SiO₂). A totalweight of about 45 g of high purity isobutylene (HPIB) containinggreater than about 99.9 wt % isobutylene was charged to a 500 mlpressure bottle and cooled using an ice/salt bath to a temperature ofabout −5° C. Catalyst system example 7 (about 0.2 g) was added to theisobutylene reaction mixture with stirring. After about 20 minutes, thereaction mixture was filtered to remove the catalyst system and thenheated at about 75° C. for about 2 hours to remove unreactedisobutylene. Optionally, the crude reaction mixture may be washed withwater. Gravimetric analysis showed conversion (amount of isobutylenethat reacted) of about 92.6%, the balance being C₈, C₁₂ and C₁₆ olefinoligomers and by-products. These oligomers and byproducts are removed inone or more stripping steps. Stripping removed some light oligomers thathad olefin isomer compositions other than contained in the actual HR-PIBpolymer. Removal of the oligomer products of low Mn further had theeffect of increasing the average product Mn.

The devolatilized reaction mixture was then heated at a temperaturesetting of about 160° C. for about 1 hour, and then at a setting ofabout 225° C. for about 1 hour. The maximum internal temperature reachedwas about 182° C. Gravimetric analysis showed conversion (amount ofisobutylene that reacted) of about 91.0%. GPC analysis showed theresulting PIB product had a Mn of about 940 daltons. ¹³C NMR showed thealpha vinylidene content to be about 79.9%.

Polymer Composition Example 3: Polymerization of isobutylene to makeHR-PIB using catalyst system example 8 (BF₃—MeOH (1:1) catalyst complexon SiO₂/Al₂O₃ support material having about 75 wt % SiO₂). A totalweight of about 45 g of high purity isobutylene (HPIB) containinggreater than about 99.9 wt % isobutylene was charged to a 500 mlpressure bottle and cooled using an ice/salt bath to a temperature ofabout −5° C. Catalyst system example 8 (about 0.2 g) was added to theisobutylene reaction mixture with stirring. After about 20 minutes, thereaction mixture was filtered to remove the catalyst system and thenheated at about 75° C. for about 2 hours to remove unreactedisobutylene. Optionally, the crude reaction mixture may be washed withwater. Gravimetric analysis showed conversion (amount of isobutylenethat reacted) of about 73.2%, the balance being C₈, C₁₂ and C₁₆ olefinoligomers and by-products. These oligomers and byproducts are removed inone or more stripping steps. Stripping removed some light oligomers thathad olefin isomer compositions other than contained in the actual HR-PIBpolymer. Removal of the oligomer products of low Mn further had theeffect of increasing the average product Mn.

The devolatilized reaction mixture was then heated at a temperaturesetting of about 160° C. for about 1 hour, and then at a setting ofabout 225° C. for about 1 hour. The maximum internal temperature reachedwas about 182° C. Gravimetric analysis showed conversion (amount ofisobutylene that reacted) of about 93.1%. GPC analysis showed theresulting PIB product had a Mn of about 924 daltons. ¹³C NMR showed thealpha vinylidene content to be about 81%.

By adjusting the catalyst composition, by for example increasing theratio of complexing agent to BF₃, and/or slowing the polymerizationreaction, the amount of alpha vinylidene content can be increased.

The examples show that solid catalyst systems for producing HR-PIB canbe made by calcining support material comprising metal oxides at varioustemperatures and subsequently adding to the support material a mixturecomprising a catalyst (e.g., BF₃ gas), a mixture comprising a catalystcomplex (e.g., BF₃/complexing agent), or combinations thereof. Thesesolid catalyst systems are dispersed in a reaction mixture to effect thepolymerization of feedstocks comprising isobutylene to polyisobutylenecompositions having desired olefin isomer content, in which the alphavinylidene isomer content is greater than about 75 wt %.

The solid catalyst systems described herein show benefits overconventional liquid catalyst systems. Because the catalyst systems aresolids, the catalyst systems can be removed by simple filtration, thuseliminating the need for extensive water washing and generating largeamounts of waste water containing BF₃ salts seen with liquid catalystsystems. Catalyst washing is very cumbersome, tedious, and generateslarge amounts of waste water that needs disposal, usually off-site.Disposal of this waste water can be expensive and limits the plant siteoptions. Also, the washed catalyst cannot be recovered or recycled.Moreover, because the solid catalyst systems are dispersible, a fixedbed is not required.

Solid catalyst systems comprising BF₃ of the present disclosure caneliminate the problem of handling toxic BF₃ gas at an HR-PIB productionsite. These solid catalyst systems can act like BF₃ gas in that they canbe complexed further on-site, as described in by method 170, withsuitable complexing agents to optimize the HR character of the PIBproduct, but without the hazards and dangers of handling BF₃ gas onsite.

In addition, using solid catalyst systems comprising BF₃ with fastreactor technology also allows for superior processability overconventional solid heterogeneous catalytic processes, particularly interms of lower reactor residence times. Lower reactor residence timescan allow for reduced equipment sizes and lower capital costs.

As is apparent from the foregoing general description and the specificembodiments, while forms of the present disclosure have been illustratedand described, various modifications can be made without departing fromthe spirit and scope of the present disclosure. Accordingly, it is notintended that the present disclosure be limited thereby. Likewise, theterm “comprising” is considered synonymous with the term “including.”Likewise whenever a composition, an element or a group of elements ispreceded with the transitional phrase “comprising,” it is understoodthat we also contemplate the same composition or group of elements withtransitional phrases “consisting essentially of,” “consisting of,”“selected from the group of consisting of,” or “is” preceding therecitation of the composition, element, or elements and vice versa.

I claim:
 1. A catalyst system comprising: a support material comprisingone or more ion exchange resins; and BF₃, wherein a concentration of BF₃is greater than about 30 wt %, based on a total weight of the catalystsystem.
 2. The catalyst system of claim 1, wherein the one or more ionexchange resins comprises an anionic exchange resin, a cationic exchangeresin, an acidic cation exchange resin, a basic anionic exchange resin,or a combination thereof.
 3. The catalyst system of claim 1, furthercomprising: a complexing agent.
 4. The catalyst system of claim 1,wherein the concentration of BF₃ is greater than about 40 wt %, based onthe total weight of the catalyst system.
 5. A catalyst systemcomprising: a support material comprising one or more ion exchangeresins; a complexing agent; and BF₃, wherein a concentration of BF₃ isgreater than about 30 wt %, based on a total weight of the catalystsystem.
 6. A method of making a catalyst system comprising: dehydratinga support material at a temperature of about 30° C. to about 200° C.,the support material comprising one or more ion exchange resins; andforming the catalyst system by adding to the support material (a) BF₃,(b) a mixture comprising BF₃ and a complexing agent, or (c) both,wherein a concentration of BF₃ is greater than about 30 wt %, based on atotal weight of the catalyst system.
 7. The method of claim 6, whereinthe one or more ion exchange resins comprises an anionic exchange resin,a cationic exchange resin, an acidic cation exchange resin, a basicanionic exchange resin, or a combination thereof.
 8. The method of claim6, further comprising: contacting the catalyst system with one or moremodifying agents.
 9. The method of claim 6, wherein the complexing agentis an oxygen containing compound or a nitrogen containing compound. 10.The method of claim 6, wherein when the catalyst system is formed byadding to the support material BF₃, a concentration of BF₃ is greaterthan about 40 wt % based on the total weight of the catalyst system. 11.The method of claim 6, wherein when the catalyst system is formed byadding to the support material the mixture comprising BF₃ and complexingagent, a mole ratio of the complexing agent to the BF₃ is between about0.5 and about
 2. 12. A method of making a polymer composition,comprising: forming a reaction mixture comprising a feedstock and acatalyst system, the feedstock comprising isobutylene, the catalystsystem comprising BF₃ and a support material comprising one or more ionexchange resins; contacting the isobutylene with the catalyst system;and obtaining the polymer composition.
 13. The method of claim 12,wherein the one or more ion exchange resins comprises an anionicexchange resin, a cationic exchange resin, an acidic cation exchangeresin, a basic anionic exchange resin, or a combination thereof.
 14. Themethod of claim 12, wherein: a concentration of BF₃ is greater thanabout 30 wt %, based on a total weight of the catalyst system; thecatalyst system further comprises a complexing agent; or a combinationthereof.
 15. The method of claim 12, wherein forming the reactionmixture comprising the feedstock and the catalyst system comprisesflowing the catalyst system into a reactor and flowing the feedstockinto the reactor, and wherein contacting the isobutylene with thecatalyst system comprises maintaining a temperature of the reactionmixture between about −35° C. and about 100° C.
 16. The method of claim12, wherein the feedstock is raffinate-1, or wherein the feedstockcomprises greater than about 20 wt % isobutylene based on a total weightof the feedstock, or a combination thereof.
 17. The method of claim 13,wherein a concentration of the catalyst system in the reaction mixtureis between about 500 ppm and about 10,000 ppm based on a total weight ofa catalyst feed, and wherein a BF₃ concentration in the reaction mixtureis between about 150 ppm and about 3,000 ppm based on the total weightof the catalyst feed.
 18. The method of claim 12, the catalyst systemfurther comprises a complexing agent.
 19. The method of claim 12,further comprising: discharging the polymer composition from a reactor;feeding the polymer composition to one or more separation apparatusesselected from the group consisting of a solid-liquid separation deviceand a distillation column; and discharging the polymer composition fromone or more of the separation apparatuses.
 20. The method of claim 12,wherein the polymer composition comprises: a polyisobutylene having a Mnof about 320 daltons to about 10,000 daltons, the polyisobutylenecomprising a first portion comprising polymer chains having alphavinylidene groups, and one or more of a second portion comprisingpolymer chains having beta vinylidene groups and a third portioncomprising polymer chains having internal vinylidene groups, wherein:the first portion is greater than about 75 wt % based on a total weightof the polymer composition, and a total content of the second portionplus the third portion is less than about 25 wt % based on the totalweight of the polymer composition.